Setting tool for expandable liner hanger and associated methods

ABSTRACT

A method of conveying an expandable liner hanger in a well includes: conveying the hanger into the well on a work string with a setting tool releasably secured to the hanger by an anchoring device; applying left-hand rotation to the work string; then lowering the work string, thereby releasing the anchoring device and permitting the setting tool to be retrieved from within the hanger. A method of setting a liner hanger includes: forcing an expansion cone through a hanger portion, thereby expanding the portion; and forcing another expansion cone into another hanger portion, thereby expanding that portion. A method of setting an expandable liner hanger includes: lowering a liner into the well; then connecting the hanger and a setting tool lower section to the liner; then lowering the hanger and the lower section into the well; and then connecting a setting tool upper section to the lower section.

BACKGROUND

The present invention relates generally to equipment utilized andoperations performed in conjunction with a subterranean well and, in anembodiment described herein, more particularly provides a setting toolfor an expandable liner hanger and associated methods.

Expandable liner hangers are generally used to secure a liner within apreviously set casing or liner string. These types of liner hangers aretypically set by expanding the liner hangers radially outward intogripping and sealing contact with the previous casing or liner string.Many such liner hangers are expanded by use of hydraulic pressure todrive an expanding cone or wedge through the liner hanger, but othermethods may be used (such as mechanical swaging, explosive expansion,memory metal expansion, swellable material expansion, electromagneticforce-driven expansion, etc.).

The expansion process is typically performed by means of a setting toolused to convey the liner hanger and attached liner into a wellbore. Thesetting tool is interconnected between a work string (e.g., a tubularstring made up of drill pipe or other segmented or continuous tubularelements) and the liner hanger.

If the liner hanger is expanded using hydraulic pressure, then thesetting tool is generally used to control the communication of fluidpressure, and flow to and from various portions of the liner hangerexpansion mechanism, and between the work string and the liner. Thesetting tool may also be used to control when and how the work string isreleased from the liner hanger, for example, after expansion of theliner hanger, in emergency situations, or after an unsuccessful settingof the liner hanger.

It is desirable to minimize a wall thickness of the setting tool andliner hanger assembly, so that equivalent circulating density (ECD) isreduced, and so that the assembly can be conveyed rapidly into the well.

It will, therefore, be appreciated that improvements are needed in theart of expandable liner hanger setting tools and associated methods ofinstalling expandable liner hangers. These improvements can includeimprovements to reduce ECD during running in, to increase operationalefficiency, convenience of assembly and operation, improvedfunctionality, etc., whether or not discussed above.

SUMMARY

In carrying out the principles of the present invention, a setting tooland associated methods are provided which solve at least one problem inthe art. One example is described below in which the setting tool usesmultiple expansion cones to expand different portions of the linerhanger. Another example is described below in which the setting tool isprovided in multiple sections which are assembled while running theliner hanger and setting tool into the well.

In one aspect, a method of conveying an expandable liner hanger in asubterranean well is provided. The method includes the steps of:conveying the liner hanger into the well on a work string with a settingtool releasably secured to the liner hanger by an anchoring device;applying left-hand rotation to the work string; and then lowering thework string, thereby releasing the anchoring device and permitting thesetting tool to be retrieved from within the liner hanger.

In another aspect, a method of setting an expandable liner hanger in asubterranean well is provided which includes the steps of: forcing anexpansion cone through a portion of the liner hanger, thereby expandingthe liner hanger portion radially outward; and forcing another expansioncone into another portion of the liner hanger, thereby expanding thesecond liner hanger portion radially outward.

In yet another aspect, a method of setting an expandable liner hanger ina subterranean well is provided which includes the steps of: lowering aliner into the well; then connecting the liner hanger and a lowersection of a setting tool to the liner; then lowering the liner hangerand the lower section into the well; and then connecting an uppersection of the setting tool to the lower section.

In a further aspect, a method of setting an expandable liner hanger in asubterranean well is provided which includes the steps of: applying apressure differential between an inner flow passage of a setting tooland an annulus formed between the setting tool and a wellbore, thepressure differential causing the setting tool to begin to expand theliner hanger; and applying a biasing force to a bypass closure as aresult of the pressure differential acting on a piston area of thebypass closure, thereby causing the bypass closure to displace andprovide fluid communication between the flow passage and the annulus.

These and other features, advantages, benefits and objects of thepresent invention will become apparent to one of ordinary skill in theart upon careful consideration of the detailed description ofrepresentative embodiments of the invention hereinbelow and theaccompanying drawings, in which similar elements are indicated in thevarious figures using the same reference numbers.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic partially cross-sectional view of a liner hangersetting system and associated methods which embody principles of thepresent invention;

FIGS. 2A-G are cross-sectional views of successive axial sections of aliner hanger setting tool and expandable liner hanger which may be usedin the system and method of FIG. 1, the setting tool and liner hangerbeing illustrated in a run-in configuration;

FIGS. 3A & B are cross-sectional views of portions of the setting toolafter compressive force and torque have been applied from a work stringto the setting tool in a release procedure;

FIGS. 4A-H are cross-sectional views of the setting tool at theconclusion of a liner hanger expansion procedure;

FIGS. 5A-C are cross-sectional views of steps in a procedure ofassembling axial sections of the setting tool during installation;

FIG. 6 is a cross-sectional view of a clamping arrangement used tosecure portions of the setting tool relative to each other during theassembly procedure; and

FIGS. 7A & B are cross-sectional views of a bypass configuration whichmay be used in the setting tool, the bypass being closed in FIG. 7A, andthe bypass being open in FIG. 7B.

DETAILED DESCRIPTION

It is to be understood that the various embodiments of the presentinvention described herein may be utilized in various orientations, suchas inclined, inverted, horizontal, vertical, etc., and in variousconfigurations, without departing from the principles of the presentinvention. The embodiments are described merely as examples of usefulapplications of the principles of the invention, which is not limited toany specific details of these embodiments.

In the following description of the representative embodiments of theinvention, directional terms, such as “above”, “below”, “upper”,“lower”, etc., are used for convenience in referring to the accompanyingdrawings. In general, “above”, “upper”, “upward” and similar terms referto a direction toward the earth's surface along a wellbore, and “below”,“lower”, “downward” and similar terms refer to a direction away from theearth's surface along the wellbore.

Representatively illustrated in FIG. 1 is a liner hanger setting system10 and associated method which embody principles of the presentinvention. In this system 10, a casing string 12 has been installed andcemented within a wellbore 14. It is now desired to install a liner 16extending outwardly from a lower end of the casing string 12, in orderto further line the wellbore 14 at greater depths.

Note that, in this specification, the terms “liner” and “casing” areused interchangeably to describe tubular materials which are used toform protective linings in wellbores. Liners and casings may be madefrom any material (such as metals, plastics, composites, etc.), may beexpanded or unexpanded as part of an installation procedure, and may besegmented or continuous. It is not necessary for a liner or casing to becemented in a wellbore. Any type of liner or casing may be used inkeeping with the principles of the present invention.

As depicted in FIG. 1, an expandable liner hanger 18 is used to seal andsecure an upper end of the liner 16 near a lower end of the casingstring 12. Alternatively, the liner hanger 18 could be used to seal andsecure the upper end of the liner 16 above a window (not shown inFIG. 1) formed through a sidewall of the casing string 12, with theliner extending outwardly through the window into a branch or lateralwellbore. Thus, it will be appreciated that many differentconfigurations and relative positions of the casing string 12 and liner16 are possible in keeping with the principles of the invention.

A setting tool 20 is connected between the liner hanger 18 and a workstring 22. The work string 22 is used to convey the setting tool 20,liner hanger 18 and liner 16 into the wellbore 14, conduct fluidpressure and flow, transmit torque, tensile and compressive force, etc.The setting tool 20 is used to facilitate conveyance and installation ofthe liner 16 and liner hanger 18, in part by using the torque, tensileand compressive forces, fluid pressure and flow, etc. delivered by thework string 22.

At this point, it should be specifically understood that the principlesof the invention are not to be limited in any way to the details of thesystem 10 and associated methods described herein. Instead, it should beclearly understood that the system 10, methods, and particular elementsthereof (such as the setting tool 20, liner hanger 18, liner 16, etc.)are only examples of a wide variety of configurations, alternatives,etc. which may incorporate the principles of the invention.

Referring additionally now to FIGS. 2A-G, detailed cross-sectional viewsof successive axial portions of the liner hanger 18 and setting tool 20are representatively illustrated. FIGS. 2A-G depict a specificconfiguration of one embodiment of the liner hanger 18 and setting tool20, but many other configurations and embodiments are possible withoutdeparting from the principles of the invention.

The liner hanger 18 and setting tool 20 are shown in FIGS. 2A-G in theconfiguration in which they are conveyed into the wellbore 14. The workstring 22 is attached to the setting tool 20 at an upper threadedconnection 24, and the liner 16 is attached to the liner hanger 18 at alower threaded connection 26 when the overall assembly is conveyed intothe wellbore 14.

The setting tool 20 is releasably secured to the liner hanger 18 bymeans of an anchoring device 28 (see FIG. 2G) which includes collets 30engaged with profiles or recesses 32 formed in an outer housing 34 ofthe liner hanger. When operatively engaged with the recesses 32 andoutwardly supported by a support sleeve 36, the collets 30 permittransmission of torque and axial force between the setting tool 20 andthe liner hanger 18.

The anchoring device 28 can be conveniently released at the conclusionof the setting operation as described more fully below. Briefly, thework string 22 can be lowered after the setting operation to therebycause the support sleeve 36 to displace downward, so that the supportsleeve no longer outwardly supports the collets 30, enabling the settingtool 20 to be retrieved from within the liner hanger 18.

In addition, the anchoring device 28 can be released, even if thesetting tool 20 has not successfully set the liner hanger 18, byrotating the work string 22 to the left (counter-clockwise as viewedfrom the surface) and then downwardly displacing the work string.

The work string 22 is connected to a generally tubular inner mandrelassembly 44 through which the flow passage 40 extends. The threadedconnection 24 (between the work string 22 and the setting tool 20) is atan upper end of the inner mandrel 44 assembly (see FIG. 2A).

The support sleeve 36 is part of the inner mandrel assembly 44, which isprevented from displacing downwardly relative to the outer housingassembly 48 by dogs or engagement members 38. However, if sufficientdownward force is applied to an outer release sleeve 84 to cause shearscrews 46 to shear, the release sleeve will be permitted to displacedownwardly, releasing the members 38 from their engagement with theinner mandrel assembly 44, and the inner mandrel assembly (including thesupport sleeve 36) will displace downwardly, thereby unsupporting thecollets 30 and allowing them to disengage from the recesses 32.

In FIGS. 3A & B, portions of the setting tool 20 are representativelyillustrated after the inner mandrel 44 has displaced downward relativeto the outer housing assembly 48. In FIG. 3A, the sheared screws 46 canbe seen, along with the downwardly displaced release sleeve 84, thedisengagement of the members 38 from the inner mandrel assembly 44, andthe manner in which the inner mandrel assembly is downwardly displaced.

To apply the downwardly directed force to the release sleeve 84, thework string 22 is used to rotate an upper connector housing 86counter-clockwise, and to then downwardly displace the connectorhousing. Inner lugs 88 formed in the connector housing 86 are engagedwith a ratchet or J-slot profile 90 formed externally on the innermandrel assembly 44.

Typically, the engagement between the lugs 88 and the J-slot profile 90prevents downward displacement of the connector housing 86 relative tothe inner mandrel assembly 44, but if the connector housing is firstrotated counter-clockwise, so that the lugs 88 enter a downwardlyelongated portion of the J-slot profile 90, then the connector housingcan displace downwardly relative to the inner mandrel assembly. Theconnector housing 86 can then contact and apply a downwardly directedforce to the release sleeve 84, thereby shearing the shear screws 46,releasing the members 38, and enabling the inner mandrel assembly 44 todisplace downwardly relative to the outer housing assembly 48 asdiscussed above.

In FIG. 3B, it may be seen that the collets 30 are no longer outwardlysupported by the support sleeve 36. The collets 30 can now be releasedfrom the recesses 32 by raising the inner mandrel assembly 44 (i.e., bypicking up on the work string 22). Locking dogs 50 prevent the supportsleeve 36 from again supporting the collets 30 as the inner mandrelassembly 44 is raised.

Note that the setting tool 20 can be released from the liner hanger 18at any time. For example, the anchoring device 28 would typically bereleased after the liner hanger 18 is set in the casing string 12 (i.e.,by lowering the work string 22 to downwardly displace the support sleeve36, and then raising the work string to withdraw the setting tool 20from the liner hanger), or the anchoring device could be released as acontingency procedure in the event that the liner 16 gets stuck in thewellbore 14 (i.e., by rotating the work string counter-clockwise, thenlowering the work string to release the members 38 and downwardlydisplace the support sleeve, and then raising the work string towithdraw the setting tool 20 from the liner hanger).

Returning to FIGS. 2A-G, the setting tool 20 is actuated to set theliner hanger 18 by dropping or circulating a ball or other type of plug(not shown) into the flow passage 40, so that the plug engages a sealsurface 92 (see FIG. 2F) formed in the inner mandrel assembly 44.Increased pressure is applied to the flow passage 40 (via the interiorof the work string 22) above the plug to thereby increase a pressuredifferential from the flow passage to an exterior of the setting tool20. The exterior of the setting tool 20 corresponds to an annulus 52between the wellbore 14 (or the interior of the casing string 12) andthe work string 22, setting tool 20, liner hanger 18 and liner 16.

The increased pressure differential is applied across three pistons 60interconnected in the outer housing assembly 48 (see FIGS. 2C & D). Anupper side of each piston 60 is exposed to pressure in the flow passage40 via ports 62 in the inner mandrel 44, and a lower side of each pistonis exposed to pressure in the annulus 52 via ports 64 in the outerhousing assembly 48.

A venting device 70 is provided to vent the flow passage 40 to theannulus 52 if a pressure differential across the venting device reachesa predetermined limit. The venting device 70 is representativelyillustrated in the drawings as a rupture disk, but other types ofventing devices, pressure relief devices, etc. may be used, if desired.

An expansion cone 66 is positioned at a lower end of the outer housingassembly 48. The expansion cone 66 is depicted as a two-piece elementhaving a lower frusto-conical surface 68 formed thereon which is driventhrough the interior of the liner hanger 18 to outwardly expand theliner hanger. The term “expansion cone” as used herein is intended toencompass equivalent structures which may be known to those skilled inthe art as wedges or swages, whether or not those structures includeconical surfaces.

Note that only a small upper portion of the liner hanger 18 overlaps theexpansion cone 66. This configuration beneficially reduces the requiredouter diameter of the setting tool 20 and liner hanger 18 assembly,which thereby reduces the equivalent circulating density whilecirculating through the assembly, and enables the assembly to beconveyed more rapidly into the well.

The differential pressure across the pistons 60 causes each of thepistons to exert a downwardly biasing force on the expansion cone 66 viathe remainder of the outer housing assembly 48. These combined biasingforces drive the expansion cone 66 downwardly through the interior ofthe liner hanger 18, thereby expanding the liner hanger.

Although three of the pistons 60 are illustrated in the drawings anddescribed above, any greater or lesser number of pistons may be used. Ifgreater biasing force is needed for a particular setting tool/linerhanger configuration, then more pistons 60 may be provided. Greaterbiasing force may also be obtained by increasing a piston area of eachof the pistons 60.

The setting tool 20 and liner hanger 18 are representatively illustratedin FIGS. 4A-H after the liner hanger has been expanded. Note that theexpansion cone 66 has been displaced downward through the liner hanger18 to thereby expand the liner hanger radially outward.

In another important feature of the setting tool 20, another expansioncone 72 is provided on an exterior of the outer housing assembly 48.This additional expansion cone 72 engages an upper end 76 of the linerhanger 18 at the conclusion of the setting process, to thereby provide asmooth, enlarged entry for subsequent access to the interior of theliner 16 after the setting tool 20 is retrieved. Once expanded by thecone 72, the upper end 76 of the liner hanger 18 has a larger innerdiameter D than the inner diameter d of the liner hanger as expanded bythe lower expansion cone 66.

Note that, when the outer housing assembly 48 has displaced downward apredetermined distance relative to the inner mandrel assembly 44, abypass closure 94 will be contacted and displaced downward by the outerhousing assembly to thereby open ports 74 and provide fluidcommunication between the exterior of the setting tool 20 and aninternal chamber 78 exposed to a lower side of one of the pistons 60(see FIGS. 4E, 7A & 7B). Since the chamber 78 is also in communicationwith the ports 64 below the piston 60, this operates to equalizepressure between the flow passage 40 and the annulus 52 (or at leastprovide a noticeable pressure drop at the surface to indicate that thesetting operation is successfully concluded).

An alternative way of downwardly displacing the bypass closure 94 is toincrease pressure in the passage 40 above the plug sufficiently to shearone or more shear screws 96. The bypass closure 94 has an internaldifferential pressure area formed therein which causes the sleeve to bebiased downwardly by the pressure differential from the passage 40 tothe annulus 52. Preferably, the shear screw 96 is configured so that thepressure differential required to shear the shear screw is greater thanthat required to displace the expansion cone 66 and expand the linerhanger 18 sufficiently, but is less than the pressure differentialrequired to open the venting device 70.

The bypass closure 94 will, thus, displace downwardly after the shearscrew 96 has sheared, thereby opening the ports 74. A snap ring 98 willprevent the sleeve 94 from displacing upward to close the ports 74. InFIG. 7A, the bypass closure 94 is depicted prior to the shear screw 96being sheared, and in FIG. 7B the bypass closure is depicted after it isdisplaced downward to open the ports 74.

Note that, if during a normal setting operation the outer housingassembly 48 is displaced downwardly sufficiently far relative to theinner mandrel assembly 44, so that the outer housing assembly contactsand biases the bypass closure 94 downwardly, it merely needs to shearthe shear screw 96. Once the shear screw 96 is sheared, the differentialpressure across the piston area in the sleeve 94 will cause the sleeveto displace downward further to open the ports 74. In this manner, thesleeve 94 opens a relatively large flowpath, and does so relativelyquickly, thereby minimizing any erosive effects caused as the pressurein the flow passage 40 is equalized with the pressure in the annulus 52.

With the liner hanger 18 expanded as depicted in FIGS. 4A-H, externalseals 206 on the liner hanger 18 would now sealingly and grippinglyengage the interior of the casing string 12 in the system of FIG. 1. Theinner mandrel assembly 44 can now be displaced downward (i.e., byslacking off on the work string 22) to release the anchoring device 28as described above. The setting tool 20 can then be retrieved from thewell.

The setting tool 20 is quite long when assembled so, for purposes ofconvenient handling, storage, transport, etc., the setting tool includesfeatures which enable it to be assembled as the liner 16, liner hanger18 and setting tool are being installed into the wellbore 14. Inparticular, separate sections of the outer housing assembly 48 and innermandrel assembly 44 can be connected together as the setting tool 20 isbeing installed.

In FIG. 5A, it can be seen that a lower section of the inner mandrelassembly 44 a and a lower section of the outer housing assembly 48 ahave been connected to the liner hanger 18 at the top of the liner 16.The liner hanger 18 and liner 16 are not visible in FIG. 5A, but it willbe appreciated that they are connected to the lower section of thesetting tool 20 as described above (e.g., with the collets 30 engaged inthe recesses 32 and the expansion cone 66 received within the upper endof the liner hanger).

The liner 16 and liner hanger 18 have been lowered into the well, andslips 54 of a drilling rig (not shown) now support the liner, linerhanger and the lower section of the setting tool 20. A spacer block 56supports a coupling 80 a of the inner mandrel assembly 44 a in positionabove a coupling 82 of the outer housing assembly 48 a. This keeps theinner mandrel assembly 44 a from displacing downwardly relative to theouter housing assembly 48 a, which would otherwise operate to releasethe anchoring device 28. A lift coupling 100 is temporarily connected toan upper end of the coupling 80 a for use in lifting the lower sectionof the setting tool 20 and the liner hanger 18, so that they can beconnected to the liner 16 when it is suspended in the slips 54.

Referring additionally now to FIG. 5B, it may be seen that the liftcoupling 100 has been removed, and an upper section of the inner mandrelassembly 44 b and an upper section of the outer housing assembly 48 bare now positioned for connecting to the lower section of the innermandrel 44 a the lower section of the outer housing assembly 48 a. Toconnect these assemblies 44 a, b and 48 a, b, an upper coupling 80 b onthe inner mandrel assembly 44 b is threaded onto the lower coupling 80 a(at which point the inner mandrel assembly 44 is complete and cansupport the lower sections), the spacer block 56 is then removed, and anouter sleeve 102 is displaced downward to connect the outer housingsections.

Referring additionally now to FIG. 5C, the setting tool 20 isillustrated after the upper and lower inner mandrel assembly sections 44a, b and the upper and lower outer housing assembly sections 48 a, bhave been connected to each other, and the setting tool is ready to belowered into the well. Note that the coupling 80 a, b joins serratedends of the upper and lower inner mandrel assembly sections 44 a, b tothereby permit torque to be transmitted through the inner mandrelassembly. Note, also, that the outer sleeve 102 is secured to the upperouter housing section 48 b with a threaded connection 104 and abuts ashoulder 106 on the coupling 82, so that compressive force can betransmitted from the upper outer housing assembly section to the lowersection during the setting process.

Referring additionally now to FIG. 6, a clamp 108 is used to secure theouter housing assembly 48 relative to the inner mandrel assembly 44during the connection process depicted in FIGS. 5B & C. The clamp 108supports the upper outer housing assembly section 48 b until it isconnected to the lower outer housing assembly section 48 a by the outersleeve 102. After the two sections of the outer housing assembly 48 areconnected, the clamp 108 is removed, so that relative displacementbetween the outer housing assembly and the inner mandrel assembly 44 ispermitted, for example, during the setting process or when releasing theanchoring device 28.

By providing the setting tool 20 in multiple sections which can beeasily, quickly and conveniently assembled as the setting tool, linerhanger 18 and liner 16 are being installed in the well, storage andtransport of the setting tool is made more practical and economical. Forexample, the separate sections of the setting tool 20 can more readilybe accommodated on standard trucks, boats and other shipping means, canmore readily be hoisted onto an offshore rig, can be more readilystored, can be more easily assembled, etc.

It may now be fully appreciated that the system 10, setting tool 20 andassociated methods described above provide significant improvements inthe art of setting expandable liner hangers. These improvements include,but are not limited to, the use of the additional expansion cone 72 toenlarge the upper end 76 of the liner hanger 18, the provision of thecontingency release wherein a counter-clockwise (left-hand) rotation ofthe work string 22 followed by lowering the work string operates torelease the anchoring device 28, the bypass closure 94 which opens alarge flow area quickly, and the assembly of upper and lower sections ofthe setting tool as it is being installed in the well.

The above disclosure, in particular, provides a method of setting anexpandable liner hanger 18 in a subterranean well, with the methodincluding the steps of: lowering a liner 16 into the well; thenconnecting the liner hanger 18 and a lower section 44 a, 48 a of asetting tool 20 to the liner 16; then lowering the liner hanger 18 andthe lower section 44 a, 48 a into the well; and then connecting an uppersection 44 b, 48 b of the setting tool 20 to the lower section 44 a, 48a.

The step of connecting the upper section of the setting tool 20 to thelower section of the setting tool 20 may include connecting an uppersection 48 b of an outer housing assembly 48 to a lower section 48 a ofthe outer housing assembly 48.

The step of connecting the upper section of the setting tool 20 to thelower section of the setting tool 20 may also include the step ofconnecting an upper section 44 b of an inner mandrel assembly 44 to alower section 44 a of the inner mandrel assembly 44 prior to the step ofconnecting the upper section 48 b of the outer housing assembly 48 tothe lower section 48 a of the outer housing assembly 48.

The method may include the step of releasably securing the upper section48 b of the outer housing assembly 48 to the upper section 44 b of theinner mandrel assembly 44 prior to the step of connecting the uppersection 48 b of the outer housing assembly 48 to the lower section 48 aof the outer housing assembly 48.

The method may also include the step of displacing the outer housingassembly 48 relative to the inner mandrel assembly 44 to thereby expandthe liner hanger 18.

Also provided by the above disclosure is a method of setting anexpandable liner hanger 18 in a subterranean well, with the methodincluding the steps of: forcing a first expansion cone 66 through afirst portion of the liner hanger 18 (e.g., at the seals 206), therebyexpanding the first portion radially outward; and forcing a secondexpansion cone 72 into a second portion of the liner hanger 18 (e.g., atthe upper end 76), thereby expanding the second portion radiallyoutward.

The second portion may be an end 76 of the liner hanger 18. The firstand second expansion cones 66, 72 may be longitudinally spaced apartalong a setting tool 20 received in the liner hanger 18.

The first expansion cone 66 forcing step may include expanding the linerhanger 18 first portion to a first internal dimension d, the secondexpansion cone 72 forcing step may include expanding the liner hanger 18second portion to a second internal dimension D, and the second internaldimension D may be greater than the first internal dimension d. Thesecond internal dimension D may be formed by the second expansion cone72 at an end 76 of the liner hanger 18.

The above disclosure also describes a method of setting an expandableliner hanger 18 in a subterranean well, with the method including thesteps of: applying a pressure differential between an inner flow passage40 of a setting tool 20 and an annulus 52 formed between the settingtool 20 and a wellbore 14, the pressure differential causing the settingtool 20 to begin to expand the liner hanger 18; and applying a biasingforce to a bypass closure 94 as a result of the pressure differentialacting on a piston area of the bypass closure 94, thereby causing thebypass closure to displace and provide fluid communication between theflow passage 40 and the annulus 52.

The biasing force applying step may include displacing an outer housingassembly 48 relative to an inner mandrel assembly 44 of the setting tool20, thereby causing the outer housing assembly 48 to contact the bypassclosure 94.

The biasing force applying step may include increasing the biasing forceto a predetermined level to thereby shear a shear member 96.

Also described by the above disclosure is a method of conveying anexpandable liner hanger 18 in a subterranean well, with the methodincluding the steps of: conveying the liner hanger 18 into the well on awork string 22 with a setting tool 20 releasably secured to the linerhanger 18 by an anchoring device 28; applying left-hand rotation to thework string 22; and then lowering the work string 22, thereby releasingthe anchoring device 28 and permitting the setting tool 20 to beretrieved from within the liner hanger 18.

The anchoring device 28 may secure an inner mandrel assembly 44 of thesetting tool 20 relative to the liner hanger 18. The step of applyingleft-hand rotation may include rotating the work string 22 relative tothe inner mandrel assembly 44.

The step of rotating the work string 22 relative to the inner mandrelassembly 44 may include displacing a lug 88 in a J-slot 90.

The step of lowering the work string 22 may include releasing anengagement member 38 which previously prevented displacement of theinner mandrel assembly 44 relative to the outer housing assembly 48.

Of course, a person skilled in the art would, upon a carefulconsideration of the above description of representative embodiments ofthe invention, readily appreciate that many modifications, additions,substitutions, deletions, and other changes may be made to thesespecific embodiments, and such changes are within the scope of theprinciples of the present invention. Accordingly, the foregoing detaileddescription is to be clearly understood as being given by way ofillustration and example only, the spirit and scope of the presentinvention being limited solely by the appended claims and theirequivalents.

1. A method of setting an expandable liner hanger in a subterraneanwell, the method comprising the steps of: lowering a liner into thewell; then connecting the liner hanger and a lower section of a settingtool to the liner; then lowering the liner hanger and the lower sectioninto the well; and then connecting an upper section of the setting toolto the lower section.
 2. The method of claim 1, wherein the step ofconnecting the upper section of the setting tool to the lower section ofthe setting tool further comprises connecting an upper section of anouter housing assembly to a lower section of the outer housing assembly.3. The method of claim 2, wherein the step of connecting the uppersection of the setting tool to the lower section of the setting toolfurther comprises the step of connecting an upper section of an innermandrel assembly to a lower section of the inner mandrel assembly priorto the step of connecting the upper section of the outer housingassembly to the lower section of the outer housing assembly.
 4. Themethod of claim 3, further comprising the step of releasably securingthe upper section of the outer housing assembly to the upper section ofthe inner mandrel assembly prior to the step of connecting the uppersection of the outer housing assembly to the lower section of the outerhousing assembly.
 5. The method of claim 3, further comprising the stepof displacing the outer housing assembly relative to the inner mandrelassembly to thereby expand the liner hanger.
 6. A method of setting anexpandable liner hanger in a subterranean well, the method comprisingthe steps of: forcing a first expansion cone through a first portion ofthe liner hanger, thereby expanding the first portion radially outward;and forcing a second expansion cone into a second portion of the linerhanger, thereby expanding the second portion radially outward.
 7. Themethod of claim 6, wherein the second portion is an end of the linerhanger.
 8. The method of claim 6, wherein the first and second expansioncones are longitudinally spaced apart along a setting tool received inthe liner hanger.
 9. The method of claim 6, wherein the first expansioncone forcing step further comprises expanding the liner hanger firstportion to a first internal dimension, wherein the second expansion coneforcing step further comprises expanding the liner hanger second portionto a second internal dimension, and wherein the second internaldimension is greater than the first internal dimension.
 10. The methodof claim 9, wherein the second internal dimension is formed by thesecond expansion cone at an end of the liner hanger.
 11. A method ofsetting an expandable liner hanger in a subterranean well, the methodcomprising the steps of: applying a pressure differential between aninner flow passage of a setting tool and an annulus formed between thesetting tool and a wellbore, the pressure differential causing thesetting tool to begin to expand the liner hanger; and applying a biasingforce to a bypass closure as a result of the pressure differentialacting on a piston area of the bypass closure, thereby causing thebypass closure to displace and provide fluid communication between theflow passage and the annulus.
 12. The method of claim 11, wherein thebiasing force applying step further comprises displacing an outerhousing assembly relative to an inner mandrel assembly of the settingtool, thereby causing the outer housing assembly to contact the bypassclosure.
 13. The method of claim 11, wherein the biasing force applyingstep further comprises increasing the biasing force to a predeterminedlevel to thereby shear a shear member.
 14. A method of conveying anexpandable liner hanger in a subterranean well, the method comprisingthe steps of: conveying the liner hanger into the well on a work stringwith a setting tool releasably secured to the liner hanger by ananchoring device; applying left-hand rotation to the work string; andthen lowering the work string, thereby releasing the anchoring deviceand permitting the setting tool to be retrieved from within the linerhanger.
 15. The method of claim 14, wherein the anchoring device securesan inner mandrel assembly of the setting tool relative to the linerhanger, and wherein the step of applying left-hand rotation furthercomprises rotating the work string relative to the inner mandrelassembly.
 16. The method of claim 15, wherein the step of rotating thework string relative to the inner mandrel assembly further comprisesdisplacing a lug in a J-slot.
 17. The method of claim 15, wherein thestep of lowering the work string further comprises releasing anengagement member which previously prevented displacement of the innermandrel assembly relative to the outer housing assembly.